A Study on Distributions of Electromagnetic Force of the Dissimilar Metal Joining in MPW Using a FEM

Shim, Ji-Yeon; Kang, Bong-Yong; Kim, Ill Soo; Kang, Moon-Jin; Park, D.H.; Kim, I.J.

doi:10.4028/www.scientific.net/amr.83-86.214

Cited by 9 publications

(9 citation statements)

References 9 publications

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“…The EM pressure (p) is directly proportional to both the discharge energy (U) and its frequency (f) [11,47,48]. A higher value of the equivalent inductance of the discharge circuit (L t ) will result in a greater loss of energy and will reduce the generated EM field and pressure [45,49].…”

Section: Variable Symbol Dimensionmentioning

confidence: 99%

Analytical Estimation of Electromagnetic Pressure, Flyer Impact Velocity, and Welded Joint Length in Magnetic Pulse Welding

Shotri

Faes

Racineux

et al. 2022

Metals

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Magnetic pulse welding involves the joining of two metallic parts in a solid state by the use of a short and intense electromagnetic impulses and the resulting impact between the parts. The coalesced interface undergoes visco-plastic deformation at a high strain rate and exhibits a wavy shape at a microscopic scale. A practical estimation of the electromagnetic pressure, impact velocity and welded joint length as a function of the process conditions and the electromagnetic coil geometry is required but currently not available. Three novel analytical relations for the estimation of the electromagnetic pressure, impact velocity, and welded joint length for magnetic pulse welding of tubes and sheets, are presented. These relations were developed systematically, following a dimensional analysis, and validated for a wide range of conditions from independent literature. The comparison of the analytically computed results and the corresponding values reported in the literature has illustrated that the proposed analytical relations can be used for the estimation of the electromagnetic pressure and impact velocity for the magnetic pulse welding of tubes and sheets with a good level of confidence. The analytically calculated results for the welded joint length show a little discrepancy with the corresponding experimentally measured values. Further investigations and more experimentally measured results are required to arrive at a more comprehensive analytical relation for the prediction of welded joint length.

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Section: Variable Symbol Dimensionmentioning

confidence: 99%

Analytical Estimation of Electromagnetic Pressure, Flyer Impact Velocity, and Welded Joint Length in Magnetic Pulse Welding

Shotri

Faes

Racineux

et al. 2022

Metals

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show abstract

“…However, factors of consideration can generally be put into two categories: the shape and the mechanical/electrical properties of the material. 13 Most commonly, compression, expansion, and flat working coils are utilized in the MPW process. The compression type is located outside the workpiece and is used for welding the flyer workpiece inward in a radial direction.…”

Section: Introductionmentioning

confidence: 99%

Selection of design parameters of working coil for Al/Cu tubular Magnetic Pulse Welding

Shim,

Kim

2023

Advances in Mechanical Engineering

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MPW produces a high Lorentz force for welding through the interaction of magnetic fields between the working coil and outer workpiece. Therefore, the design of the working coil is crucial in the MPW process. In particular, it is important to understand and estimate the distribution of Lorentz force on the outer tube and the stress on the working coil. These factors greatly impact the efficiency of energy delivery and the durability of the process. The purpose of this research was to analyze the effect of coil design parameters on the Lorentz force and stress. The ultimate objective was to optimize these design parameters specifically for welding tubular workpieces; for this, an electromagnetic-mechanical FE-model was developed. The design parameters considered in this study included the angle, radius, and protruding length. The Lorentz force and stress were calculated based on these parameters. Notably, the response surface method (RSM) and sequential quadratic programing (SQP) were utilized to develop a prediction model and optimize the design parameters, respectively. The findings revealed that the protruding length and angle are significant design parameters. Consequently, a working coil was manufactured using the optimized design parameters, leading to a successful Al/Cu joint. These results emphasize the indispensability of optimizing design parameters to achieve high-quality joints.

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“…Casalino et al [5] used the finite element method to analyze the influence of thermal energy distribution, sheet deformation and different discharge parameters on the quality of MPW. Shim et al [6] established an MPW model through FEM, and studied the distribution of electromagnetic force by taking current and frequency as loading conditions. Shim and Kang [7] established a 3D FEM simulation model to analyze the electromagnetic force distribution of the square coil.…”

Section: Introductionmentioning

confidence: 99%

Multiphysics Numerical Simulation of the Transient Forming Mechanism of Magnetic Pulse Welding

Yang

et al. 2022

Metals

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Magnetic pulse welding (MPW) is widely used in the connection of dissimilar metals. The welding process involves the coupling of the electromagnetic field and structural field, which is a high-energy transient forming process. Based on the current experimental methods, it is difficult to capture the relevant data in the process of magnetic pulse welding, and the transient forming mechanism of magnetic pulse welding needs to be further studied. Taking the magnetic pulse welding of an Al-Mg sheet as an example, based on the Ansoft Maxwell and ANSYS finite element simulation platform, the loose coupling method was used to analyze an electromagnetic field generated by the discharging capacitor bank and structural field of the Al-Mg sheet under the action of electromagnetic force. The discharge period of the magnetic pulse welding capacitor bank was 62 μs. The current direction in the aluminum sheet changed once half a cycle, and the direction of the electromagnetic force was always consistent with the Z-axis. Under the skin effect, the magnetic induction intensity on the lower surface of the aluminum sheet was the largest. At 16 μs, the induced current, electromagnetic force and magnetic induction intensity in the aluminum sheet reached the peak values, which were 7.89 A/m2, 4.58 N/m3 and 12.6 T, respectively. The maximum electromagnetic force and velocity in the structural field were 2400 KN and 300 m/s. The structure field simulation reproduces the transient forming process of magnetic pulse welding, and clarifies the formation mechanism of the “intermediate zone rebound uncomposite zone-welding bonding zone-unbound zone”. Based on the numerical simulation technology, the research on the transient forming mechanism of magnetic pulse welding under multiphysics simulations can promote the development and application of magnetic pulse welding technology and better guide engineering practices.

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A Study on Distributions of Electromagnetic Force of the Dissimilar Metal Joining in MPW Using a FEM

Cited by 9 publications

References 9 publications

Analytical Estimation of Electromagnetic Pressure, Flyer Impact Velocity, and Welded Joint Length in Magnetic Pulse Welding

Analytical Estimation of Electromagnetic Pressure, Flyer Impact Velocity, and Welded Joint Length in Magnetic Pulse Welding

Selection of design parameters of working coil for Al/Cu tubular Magnetic Pulse Welding

Multiphysics Numerical Simulation of the Transient Forming Mechanism of Magnetic Pulse Welding

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